Harmonic drive disc recliner for automotive vehicle seat

ABSTRACT

A disc recliner for a seat assembly includes a fixed plate secured to a seat cushion and a rotatable plate secured to a seat back. Each of the fixed and rotatable plates has a plurality of teeth, the number of teeth not being equal. A flex spline has a plurality of teeth, the number of teeth being equal to the number of teeth on the fixed plate. A wave generator causes a portion of the teeth on the flex spline to meshingly engage with the teeth on the fixed and rotatable plates. Rotation of the wave generator causes the teeth on the flex spline which meshingly engage with the teeth on the fixed and rotatable plates to change, thereby causing the rotatable plate to rotate relative to the fixed plate, which in turn causes the seat back to pivot relative to the seat cushion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and all the benefits of U.S.Provisional Application No. 61/491,963 filed on Jun. 1, 2011 andentitled “Harmonic Drive Disc Recliner For Automotive Vehicle Seat” andU.S. Provisional Application No. 61/522,898 filed on Aug. 12, 2011 andentitled “Seat Recliner With Harmonic Drive And Bearing Cage.”

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a vehicle seat assembly. Moreparticularly, the present invention relates to a harmonic drive discrecliner operatively coupling a seat back and seat cushion.

2. Description of Related Art

Automotive vehicles typically include one or more seat assemblies havinga seat cushion and a seat back for supporting passengers above a vehiclefloor. The seat assembly is commonly mounted directly to the vehiclefloor or, more commonly, the seat assembly is operatively coupled to thefloor by a seat track assembly for providing fore and aft slidingadjustment of the seat assembly for passenger comfort. The seat back istypically operatively coupled to the seat cushion by a recliner assemblyfor providing pivotal movement relative to the seat cushion.

For some vehicles, particularly those for the luxury market, therecliner assembly is electrically powered. A typical power seat reclinerassembly includes an electric drive motor that meshes with a series ofreduction gears. Rotation of the drive motor adjusts the recline angleof the seat back relative to the seat cushion. Forward and rearwardreclining movement of the seat back is provided through reversing thedirection of rotation of the drive motor.

It is desirable that an improved recliner assembly be compact,lightweight and low-cost. It is also desirable that an improved reclinerassembly reduce any gear backlash or “chuck.” “Chuck” refers to anyimperfection or play within the recliner assembly that allows movementof the seat back while the recliner assembly is in a locked condition.Further, it is desirable that an improved recliner assembly allows for ahigh gear ratio which allows for a smaller drive motor and less drivemotor gear reduction.

SUMMARY OF THE INVENTION

According to one aspect of the invention, a seat assembly for anautomotive vehicle includes a harmonic drive disc recliner operativelycoupling a seat back to a seat cushion to allow pivotal movement of theseat hack relative to the seat cushion. The disc recliner includes afixed plate secured to the seat cushion and a rotatable plate secured tothe seat back and rotatably coupled to the fixed plate. The fixed androtatable plates each have a plurality of teeth disposed therearoundthat extend radially inward. The number of teeth on the fixed plate doesnot equal the number of teeth on the rotatable plate. A flex spline isdisposed between the fixed and rotatable plates and includes a pluralityof teeth that extend radially outward. The flex spline has the samenumber of teeth as the fixed plate. A wave generator is disposed withinthe flex spline and has an outer profile with lobes that cause the teethon the flex spline to meshingly engage with the teeth on the fixed androtatable plates in distinct regions corresponding with the lobes. Asthe wave generator rotates, the regions where the teeth on the flexspline meshingly engage with the teeth on the fixed and rotatable plateschange and simultaneously the teeth on the flex spline urge the teeth onthe rotatable plate to align with the teeth on the fixed plate in thoseregions, thereby causing rotation of the rotatable plate relative to thefixed plate, which in turn causes the seat back to pivot relative to theseat cushion.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention will be readily appreciated as thesame becomes better understood by reference to the following detaileddescription when considered in connection with the accompanying drawingswherein:

FIG. 1 is a side view of a vehicle seat assembly including a seat backoperatively coupled to a seat cushion with a recliner assembly having aharmonic drive disc recliner;

FIG. 2 is an exploded perspective view of a harmonic drive disc reclineraccording to a first embodiment of the invention;

FIG. 3 is a side view of the disc recliner shown in FIG. 2 illustratinga wave generator causing meshing engagement between a flex spline, fixedplate, and rotatable plate;

FIG. 4 is a close-up side view of the disc recliner shown in FIG. 3;

FIG. 5 is an exploded perspective view of a harmonic drive disc reclineraccording to a second embodiment of the invention;

FIG. 6 is a side view of the disc recliner shown in FIG. 5 illustratinga wave generator causing meshing engagement between a flex spline, fixedplate, and rotatable plate;

FIG. 7 is a close-up side view of the disc recliner shown in FIG. 6;

FIG. 8 is an exploded perspective view of a harmonic drive disc reclineraccording to a third embodiment of the invention;

FIG. 9 is a perspective view of a wave generator from the disc reclinershown in FIG. 8;

FIG. 10 is a side view of the wave generator shown in FIG. 9 in rollingcontact with a flex spline;

FIG. 11 is a side view of the disc recliner shown in FIG. 8 illustratingthe wave generator causing meshing engagement between the flex spline,fixed plate, and rotatable plate;

FIG. 12 is a fragmentary perspective view of a harmonic drive discrecliner according to a fourth embodiment of the invention;

FIG. 13 is a side view of the disc recliner shown in FIG. 12illustrating the wave generator causing meshing engagement between theflex spline, fixed plate, and rotatable plate;

FIG. 14 is perspective view of a wave generator from the disc reclinershown in FIG. 12; and

FIG. 15 is a perspective view of a roller of the wave generator from thedisc recliner shown in FIG. 12.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring to the Figures, wherein like numerals indicate like orcorresponding parts throughout the several views, a seat assembly foruse in an automotive vehicle is generally shown at 10. Referring to FIG.1, the seat assembly 10 includes a generally horizontal seat cushion 12and a generally upright seat back 14 operatively coupled by a reclinerassembly 16 to the seat cushion 12. The recliner assembly 16 includes apair of spaced apart and synchronized disc recliners 18, only one ofwhich is shown,

Referring to FIGS. 1 through 4, the disc recliners 18 allow for pivotalor angular adjustment of the seat back 14 relative to the seat cushion12 about a pivot axis 20 that extends laterally or in an axialdirection. The seat back 14 is adjustable between an upright seatingposition, shown at A, and a plurality of reclined positions disposedrearwardly of the upright seating position A, one of which is shown atB. Only one of the disc recliners 18 will be described in detail,however, it is contemplated that both of the disc recliners 18 may havegenerally the same construction. The disc recliner 18 generally includesa fixed plate 22, an input shaft 24, a flex spline 26, a wave generator28, and a rotatable plate 30. In the current embodiment, the fixed plate22 is adapted to be mounted to the seat cushion 12 and the rotatableplate 30 is adapted to be mounted to the seat back 14. The fixed plate22 and the rotatable plate 30 are held together by a retaining ring 32in a manner well known in the art such that the rotatable plate 30 canrotate about the pivot axis 20 relative to the fixed plate 22. It isunderstood that rotation of the rotatable plate 30 relative to the fixedplate 22 results in pivotal movement of the seat back 14 relative to theseat cushion 12.

The fixed plate 22 is circular, generally cup-shaped, and includes anend wall 34 having a first central bore 36 extending therethrough in theaxial direction. When the disc recliner 18 is assembled, the firstcentral bore 36 is coaxial with the pivot axis 20. An outer side of theend wall 34 is adapted to be fixedly secured to the seat cushion 12 byany suitable means. A side wall 38 protrudes from the end wall 34 in theaxial direction and extends circumferentially around the fixed plate 22to define an inner surface. A first plurality of teeth 40 is disposedaround the inner surface of the side wall 38. The teeth 40 extendradially inward toward the pivot axis 20.

The rotatable plate 30 is also circular, generally cup-shaped, andincludes an end wall 42 having a second central bore 44 extendingtherethrough in the axial direction. When the disc recliner 18 isassembled, the second central bore 44 is coaxial with the pivot axis 20.An outer side 45 of the end wall 42 is adapted to be fixedly secured tothe seat back 14 by any suitable means. A side wall 46 protrudes fromthe end wall 42 in the axial direction and extends circumferentiallyaround the rotatable plate 30 to define an inner surface. A secondplurality of teeth 48 is disposed around the inner surface of the sidewall 46. The teeth 48 extend radially inward toward the pivot axis 20.

The flex spline 26 is ring-shaped and has a thin flexible wall 50. Athird plurality of teeth 52 is disposed around an outside surface of theflexible wall 50. The teeth 52 extend radially outward away from thepivot axis 20. The flex spline 26 is disposed in the axial directionbetween the fixed plate 22 and the rotatable plate 30 such that theteeth 52 on the flex spline 26 meshingly engage with the teeth 40 on thefixed plate 22 and the teeth 48 on the rotatable plate 30, as will bedescribed in further detail below.

The wave generator 28 is disposed circumferentially within the flexspline 26 and includes an outer profile that is adapted for engaging aninner surface 54 of the flex spline 26 thereby deforming the flex spline26 and causing the teeth 52 on the flex spline 26 to meshingly engagewith the teeth 40 on the fixed plate 22 and the teeth 48 on therotatable plate 30 in three distinct regions. Each region where theteeth 52 on the flex spline 26 meshingly engage with the teeth 40 on thefixed plate 22 and the teeth 48 on the rotatable plate 30 correspondswith a lobe or high point on the outer profile of the wave generator 28.

In the current embodiment, the wave generator 28 is a disc-shaped camand the outer profile includes three lobes 56 generally equally spacedapart in the circumferential direction. Thus, each lobe 56 is spacedapproximately one hundred and twenty (120) degrees apart from eachadjacent lobe 56. Each lobe 56 contacts the inner surface 54 of the flexspline 26 and applies a normal force F thereto, thereby deforming theshape of the flex spline 26. Rotation of the wave generator 28 causesthe flex spline 26 to deform to the shape of the rotating wave generator28. The flex spline 26 does not rotate with the wave generator 28, thereason for which is described below. The wave generator 28 also includesa third central bore 58 extending therethrough in the axial directionand which is adapted for receiving the input shaft 24. When the discrecliner 18 is assembled, the third central bore 58 is coaxial with thepivot axis 20. It is contemplated that the wave generator 28 could havemore than three lobes 56 causing the teeth 52 on the flex spline 26 tomeshingly engage with the teeth 40 on the fixed plate 22 and the teeth48 on the rotatable plate 30 in more than three regions.

The input shaft 24 is coaxial with the pivot axis 20 and extends in theaxial direction through the first central bore 36 of the fixed plate 22,the third central bore 58 of the wave generator 28, and the secondcentral bore 44 of the rotatable plate 30. The input shaft 24 isrotatably driven by a motor (not shown) in a first or second directiondepending on the desired direction of movement of the seat back 14.Alternatively, it is appreciated that the input shaft 24 may be manuallyrotated in the first or second direction without varying from the scopeof the invention. The wave generator 28 is coupled to the input shaft 24for rotation therewith. As the wave generator 28 rotates, the lobes 56are in sliding contact with the inner surface 54 of the flex spline 26such that rotation of the wave generator 28 creates friction between thelobes 56 and the inner surface 54. The friction, along with the normalforce F, determines the amount of torque required to rotate the inputshaft 24. As the wave generator 28 rotates, the teeth 52 on the flexspline 26 which meshingly engage with the teeth 40, 48 on the fixed androtatable plates 22, 30 change. In other words, the regions where theteeth 52 on the flex spline 26 meshingly engage with the teeth 40, 48 onthe fixed and rotatable plates 22, 30 change and revolve around thepivot axis 20 at the same rate as rotation of the wave generator 28.

In the current embodiment, the number of teeth 52 or tooth count on theflex spline 26 is equal to the number of teeth 40 or tooth count on thefixed plate 22. For example, the number of teeth 52 on the flex spline26 and the number of teeth 40 on the fixed plate 22 is one hundred andeighty (180). Since the flex spline 26 and the fixed plate 22 have thesame number of teeth there is no relative rotation between the flexspline 26 and the fixed plate 22 during rotation of the wave generator28. Rather, the teeth 52 on the flex spline 26 simply engage anddisengage with the teeth 40 on the fixed plate 22 as the wave generator28 rotates, thereby causing the flex spline 26 to flex inwardly andoutwardly. In contrast, the rotatable plate 30 has more teeth than theflex spline 26. In one embodiment, for example, the number of teeth 48or tooth count on the rotatable plate 30 is one hundred and eighty-three(183). Since the rotatable plate 30 has more teeth than the flex spline26, the rotatable plate 30 will rotate relative to the flex spline 26during rotation of the wave generator 28. More specifically, thedifferent number of teeth results in a misalignment between a profile ofthe teeth 48 on the rotatable plate 30 and a profile of the teeth 40 onthe fixed plate 22. Thus, as the wave generator 28 causes the flexspline 26 to flex outwardly, the teeth 52 on the flex spline 26 pushagainst the teeth 48 on the rotatable plate 30 to align the profile ofthe teeth 48 on the rotatable plate 30 with the profile of the teeth 40on the fixed plate 22 in the regions where the teeth 52 on the flexspline 26 meshingly engage with the teeth 40, 48 on the fixed androtatable plates 22, 30, thereby causing the rotatable plate 30 torotate relative to the flex spline 26 and the fixed plate 22.

For every full rotation of the wave generator 28, the rotatable plate 30will rotate a slight amount (three teeth, for example) backward relativeto the flex spline 26. The reduction ratio from the input shaft 24 tothe rotatable plate 30 can be calculated as:

${{reduction}\mspace{14mu} {ratio}} = \frac{{{number}\mspace{14mu} {of}\mspace{14mu} {teeth}{\mspace{11mu} \;}{on}\mspace{14mu} {f{le}x}\mspace{14mu} {spline}} - {{number}\mspace{14mu} {of}\mspace{14mu} {teeth}\mspace{14mu} {on}\mspace{14mu} {rotatable}\mspace{14mu} {plate}}}{{number}\mspace{14mu} {of}\mspace{14mu} {teeth}\mspace{14mu} {on}\mspace{14mu} {flex}\mspace{14mu} {spline}}$

For example, if the number of teeth 48 on the rotatable plate 30 is onehundred and eighty-three (183) and the number of teeth 52 on the flexspline 26 is one hundred and eighty (180), the reduction ratio is−0.0167. Thus, the rotatable plate 30 will rotate at 1/60^(th) the speedof the input shaft 24 and in the opposite direction. It is appreciatedthat the difference between the number of teeth 48 on the rotatableplate 30 and the number of teeth 52 on the flex spline 26 will depend onthe number of regions in which the teeth 52 on the flex spline 26meshingly engage with the teeth 48 on the rotatable plate 30.

Referring to FIGS. 5 through 7, in a second embodiment of the invention,the disc recliner 18 includes a wave generator 60 that is a disc-shapedcam having an outer profile with three lobes 62 generally equally spacedapart in the circumferential direction. Thus, each lobe 62 is spacedapproximately one hundred and twenty (120) degrees apart from eachadjacent lobe 62. Each lobe 62 is formed by a series of cylindricalrollers 64 set in a series of corresponding recesses 66 formed in anouter edge 68 of the wave generator 60. The rollers 64 are arranged torotate about individual axes of rotation that extend in the axialdirection and are generally parallel with the pivot axis 20. The rollers64 contact the inner surface 54 of the flex spline 26. As the wavegenerator 60 rotates, the rollers 64 are in rolling contact with theinner surface 54 of the flex spline 26, thereby reducing the frictionbetween the wave generator 60 and the flex spline 26 as compared withthe first embodiment. The reduced friction lowers the torque required torotate the input shaft 24. In the current embodiment, each lobe 62includes seven (7) rollers 64 and seven (7) corresponding recesses 66.It is appreciated, however, that any number of rollers 64 andcorresponding recesses 66 may be used without varying from the scope ofthe invention. It is contemplated that the rollers 64 could be sphericalbearings without varying from the scope of the invention. It is alsocontemplated that each lobe 62 could include a single recess elongatedin the circumferential direction with multiple rollers disposed in therecess, wherein each roller is mounted for rotation about a center axleextending in the axial direction that is generally parallel with thepivot axis 20.

Referring to FIGS. 8 through 11, in a third embodiment of the invention,the disc recliner 18 includes a wave generator 70 that is a disc-shapedcam having an outer profile with three lobes 72 generally equally spacedapart in the circumferential direction. Thus, each lobe 72 is spacedapproximately one hundred and twenty (120) degrees apart from eachadjacent lobe 72. Each lobe 72 is formed by a series of threecylindrical rollers 74 held between a first cage part 76 and a secondcage part 78. Each roller 74 is rotatably mounted on a shaft 80 thatextends in the axial direction and which is supported at each end byopenings 82 in the first and second cage parts 76, 78. In other words,the first and second cage parts 76, 78 form a bearing cage forsupporting the rollers 74 therebetween. The axis of each shaft 80 isgenerally parallel with the pivot axis 20. The first cage part 76 iscircular and is disposed adjacent to the fixed plate 22. The second cagepart 78 is also circular and includes a third central bore 84 extendingtherethrough in the axial direction. The input shaft 24 is fixedlysecured to the first cage part 76 for rotation therewith. When the discrecliner 18 is assembled, the input shaft 24 is coaxial with the pivotaxis 20 and extends from the first cage part 76 in the axial directionthrough the first central bore 36 in the fixed plate 22. The input shaft24 also extends from the first cage part 76 in the axial directionthrough the third central bore 84 in the second cage part 78 and thesecond central bore 44 in the rotatable plate 30. The rollers 74 contactthe inner surface 54 of the flex spline 26. As the wave generator 70rotates, the rollers 74 are in rolling contact with the inner surface 54of the flex spline 26, thereby reducing the friction between the wavegenerator 70 and the flex spline 26 as compared with the firstembodiment. The reduced friction lowers the torque required to rotatethe input shaft 24.

Referring to FIGS. 12 through 15, in a fourth embodiment of theinvention, the disc recliner 18 includes a wave generator 90 that is adisc-shaped cam having an outer profile with three lobes 92 generallyequally spaced apart in the circumferential direction. Thus, each lobe92 is spaced approximately one hundred and twenty (120) degrees apartfrom each adjacent lobe 92. The wave generator 90 includes a pair ofrollers 94 flanking each lobe 92 in the circumferential direction suchthat there is a total of six (6) rollers 94 in the current embodiment.Each roller 94 is disposed in a recess 96 formed in the outer profile ofthe wave generator 90. More specifically, each roller 94 includes spacedapart first and second wheels 98, 100 mounted on opposite ends of aspacer or shaft 102 that extends in the axial direction. The first andsecond wheels 98, 100 are disposed within reliefs 104 formed on eachside of the wave generator 90 and the shaft 102 is rotatably supportedin the recess 96 by the wave generator 90. The axis of each shaft 102 isgenerally parallel with the pivot axis 20. The lobes 92 and the rollers94 contact the inner surface 54 of the flex spline 26. As the wavegenerator 90 rotates, the lobes 92 are in sliding contact with the innersurface 54 of the flex spline 26 and the rollers 94 are in rollingcontact with the inner surface 54 of the flex spline 26, therebyreducing the friction between the wave generator 90 and the flex spline26 while also ensuring the teeth 52 on the flex spline 26 remainmeshingly engaged with the teeth 40, 48 on the fixed and rotatableplates 22, 30.

The invention has been described in an illustrative manner, and it is tobe understood that the terminology, which has been used, is intended tobe in the nature of words of description rather than of limitation. Manymodifications and variations of the present invention are possible inlight of the above teachings. It is, therefore, to be understood thatwithin the scope of the appended claims, the invention may be practicedother than as specifically described.

What is claimed:
 1. A disc recliner operatively coupling a seat back toa seat cushion to allow selective pivotal movement of the seat backrelative to the seat cushion about a pivot axis extending in an axialdirection, said disc recliner comprising: a first plate adapted to befixedly secured to the seat cushion, said first plate including a firstplurality of teeth disposed therearound; a second plate adapted to befixedly secured to the seat back and rotatably coupled to said firstplate, said second plate including a second plurality of teeth disposedtherearound, wherein a tooth count of said first plurality of teeth doesnot equal a tooth count of said second plurality of teeth; a flex splineincluding a flexible wall defining an inner surface and having a thirdplurality of teeth disposed radially therearound, wherein a tooth countof said third plurality of teeth equals said tooth count of said firstplurality of teeth; a wave generator having a first side facing saidfirst plate and a second side facing said second plate and an outerprofile causing a portion of said third plurality of teeth to meshinglyengage with said first plurality of teeth and said second plurality ofteeth, said outer profile of said wave generator includes a plurality oflobes generally equally spaced apart in a circumferential direction,said plurality of lobes causing said third plurality of teeth tomeshingly engage with said first plurality of teeth and said secondplurality of teeth in a plurality of distinct regions corresponding withsaid plurality of lobes and said plurality of distinct regions at whichsaid third plurality of teeth meshingly engage with said first pluralityof teeth and said second plurality of teeth change in response torotation of said wave generator; said wave generator includes a firstcage part and a second cage part, each one of said plurality of lobesincluding at least one roller rotatably supported between said first andsecond cage parts, and said at least one roller directly contacting saidinner surface of said flex spline; and wherein said second plate rotatesrelative to said first plate in response to rotation of said wavegenerator, thereby causing pivotal movement of the seat back relative tothe seat cushion. 2.-13. (canceled)
 14. A disc recliner operativelycoupling a seat back to a seat cushion to allow selective pivotalmovement of the seat back relative to the seat cushion about a pivotaxis extending in an axial direction, said disc recliner comprising: afirst plate adapted to be fixedly secured to the seat cushion, saidfirst plate including a first plurality of teeth disposed therearound; asecond plate adapted to be fixedly secured to the seat back androtatably coupled to said first plate, said second plate including asecond plurality of teeth disposed therearound, wherein a tooth count ofsaid first plurality of teeth does not equal a tooth count of saidsecond plurality of teeth; a flex spline including a flexible walldefining an inner surface and having a third plurality of teeth disposedradially therearound, wherein a tooth count of said third plurality ofteeth equals said tooth count of said first plurality of teeth; a wavegenerator having a first side facing said first plate and a second sidefacing said second plate and an outer profile causing a portion of saidthird plurality of teeth to meshingly engage with said first pluralityof teeth and said second plurality of teeth, said outer profile of saidwave generator includes a plurality of lobes generally equally spacedapart in a circumferential direction, said plurality of lobes causingsaid third plurality of teeth to meshingly engage with said firstplurality of teeth and said second plurality of teeth in a plurality ofdistinct regions corresponding with said plurality of lobes and saidplurality of distinct regions at which said third plurality of teethmeshingly engage with said first plurality of teeth and said secondplurality of teeth change in response to rotation of said wavegenerator; wherein said wave generator includes a pair of rollersflanking each one of said plurality of lobes in said circumferentialdirection, each one of said plurality of lobes directly contacting saidinner surface of said flex spline, and each one of said pair of rollersdirectly contacting said inner surface of said flex spline; and whereinsaid second plate rotates relative to said first plate in response torotation of said wave generator, thereby causing pivotal movement of theseat back relative to the seat cushion.
 15. The disc recliner as setforth in claim 14 wherein each one of said pair of rollers is rotatablysupported in a recess in said outer profile of said wave generator, andeach one of said pair of rollers rotating about an axis generallyparallel to the pivot axis.
 16. The disc recliner as set forth in claim15 wherein each one of said pair of rollers includes first and secondwheels spaced apart in the axial direction and coupled to a shaft, saidshaft having an axis generally parallel to the pivot axis and rotatablysupported in said recess, and each of said first and second wheelsdirectly contacting said inner surface of said flex spline.